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GROUP 11A
ENGINE
MECHANICAL
<2.0L ENGINE>
CONTENTS
GENERAL DESCRIPTION. . . . . . . . .
11A-2
ENGINE DIAGNOSIS. . . . . . . . . . . . .
11A-3
SPECIAL TOOLS. . . . . . . . . . . . . . . .
11A-4
ON-VEHICLE SERVICE. . . . . . . . . . .
11A-7
11A-7
11A-11
11A-12
11A-13
11A-14
11A-15
11A-16
11A-16
11A-32
11A-34
CRANKSHAFT PULLEY . . . . . . . . . .
REMOVAL AND INSTALLATION . . . . . . . .
11A-18
11A-18
11A-36
11A-29
ENGINE ASSEMBLY . . . . . . . . . . . . .
11A-26
11A-42
SPECIFICATIONS . . . . . . . . . . . . . . . 11A-46
11A-24
FASTENER TIGHTENING
SPECIFICATIONS. . . . . . . . . . . . . . . . . . . .
11A-46
11A-24
SERVICE SPECIFICATIONS . . . . . . . . . . .
11A-47
SEALANTS . . . . . . . . . . . . . . . . . . . . . . . . .
11A-47
11A-2
GENERAL DESCRIPTION
The 4G94 (2.0L) engine is an in-line four-cylinder
engine. The cylinder numbers are assigned as 1-2-34 from the front of the engine (timing belt side). This
engines firing order is 1, 3, 4, 2.
ITEMS
SPECIFICATIONS
Type
In-line SOHC
Number of cylinders
Bore mm (in)
81.5 (3.21)
Stroke mm (in)
95.8 (3.77)
1,999 (122.0)
Compression ratio
9.5
Firing order
1-3-4-2
Valve timing
Intake valve
Exhaust valve
Opens (BTDC)
Closes (ABDC)
58
Opens (BBDC)
58
Closes (ATDC)
10
M1111000100464
Lubrication system
Trochoid type
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ENGINE DIAGNOSIS
11A-3
M1111000700240
SYMPTOM
PROBABLE CAUSE
REMEDY
Noisy valves
Retighten.
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11A-4
SPECIAL TOOLS
TOOL
A
MB991824
MB991827
DO NOT USE
MB991910
MB991911
DO NOT USE
MB991914
M1111000601086
SUPERSESSION
APPLICATION
MB991958
Scan tool (MUT-III sub
assembly)
A: MB991824
Vehicle
communication
interface (V.C.I.)
B: MB991827
MUT-III USB cable
C: MB991910
MUT-III main harness
A (vehicles with CAN
communication
system)
D: MB991911
MUT-III main harness
B (vehicles without
CAN communication
system)
E: MB991914
MUT-III main harness
C (for Daimler
Chrysler models only)
F: MB991825
MUT-III measurement
adapter
G: MB991826
MUT-III trigger
harness
MB991824-KIT
Drive belt tension check
Ignition timing check
NOTE: . G: MB991826
Idle mixture check
MUT-III Trigger harness is
Curb idle speed check
not necessary when
pushing V.C.I. ENTER
CAUTION
key.
If you connect MUT-III
main harness A to a
vehicle without CAN
communication system
to use the MUT-III, a
pulse signal may
interfere with the
simulated vehicle speed
lines, thus causing the
MUT-III inoperative.
Therefore, use the MUTIII main harness B
(MB991911) instead.
MB991668
Belt tension meter set
MB991825
MB991826
MB991958
B991668
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11A-5
TOOL
SUPERSESSION
APPLICATION
MB991454
Engine hanger balancer
MZ203827-01
MB991527
Hanger
MB991895
Engine hanger
B991454
B991527
MB991895
MB991928
Engine hanger
A: MB991929
Joint (50) 2
E
B: MB991930
Joint (90) 2
A
C: MB991931
D
Joint (140) 2
B
D: MB991932
Foot (standard) 4
B991928
E: MB991933
Foot (short) 2
F: MB991934
Chain and hook
assembly
MB990767
Front hub and flange
yoke holder
MB990767-01
MD998719
Pin
MIT308239
B990767
D998719
MD998713
MD998713-01
Camshaft oil seal installer
D998713
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11A-6
TOOL
SUPERSESSION
APPLICATION
MD998717
Crankshaft front oil seal
installer
MD998717-01
MD998718
Crankshaft rear oil seal
installer
MD998718-01
MD998781
Flywheel stopper
MB991653
Cylinder head bolt
wrench
D998781
B991654
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11A-7
ON-VEHICLE SERVICE
DRIVE BELT (FOR GENERATOR, POWER
STEERING OIL PUMP AND A/C COMPRESSOR)
(CHECK CONDITION)
M1111003101002
CAUTION
To prevent damage to special tool MB991824, always turn
the ignition switch to the "LOCK" (OFF) position before
connecting or disconnecting special tool MB991824.
1. Connect special tool MB991668 to special tool MB991824.
2. Connect special tool MB991911 to special tool MB991824.
3. Connect special tool MB991911 to the data link connector.
4. Turn the ignition switch to the "ON" position and select
"Belt Tension" from the menu special tool MB991824
screen.
16-PIN
MB991824
MB991668
MB991911
AC306637 AB
15
15
MB991668
(MICROPHONE)
10 20 mm
(0.4 0.8 in)
TAP LIGHTLY
WITH A FINGER
GENERATOR
PULLEY
CRANKSHAFT
PULLEY
AC100651AB
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11A-8
CAUTION
The temperature of the surface of the belt should be as
close as possible to underhood temperature.
Do not let any contaminants such as water or oil get
onto the microphone.
If strong gusts of wind blow against the microphone or
if there are any loud sources of noise nearby, the values measured by the microphone may not correspond
to actual values.
If the microphone is touching the belt while the measurement is being made, the values measured by the
microphone may not correspond to actual values.
Do not take the measurement while the vehicle's engine
is running.
6. Gently tap the middle of the belt between the pulleys (the
place indicated by the arrow) with your finger as shown in
the illustration, and check that the vibration frequency of the
belt is within the standard value.
Standard value:
ITEM
WHEN
CHECKED
Vibration
151
frequency Hz
195
DURING
DURING
ADJUSTMENT REPLACEMENT
163
185
213
246
TENSION
GAUGE
CRANKSHAFT
PULLEY
GENERATOR
PULLEY
ITEM
WHEN
CHECKED
DURING
ADJUSTMENT
DURING
REPLACEMENT
Tension N
(lb)
294 490
(66 110)
343 441
(77 99)
588 784
(132 176)
AC100652 AB
APPROXIMATELY
100 N (22 lb)
CRANKSHAFT
PULLEY
GENERATOR
PULLEY
AC100653 AB
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ITEM
WHEN
CHECKED
DURING
ADJUSTMENT
DURING
REPLACEMENT
Deflection
(Reference
value) mm
(in)
9.7 12.7
10.3 11.8
6.7 8.5
(0.38 0.50) (0.41 0.47) (0.26 0.34)
11A-9
ADJUSTING
BOLT
CAUTION
Check after turning the crankshaft one or more rotations
clockwise.
Standard value:
LOCK BOLT
PIVOT BOLT
ITEM
AC100654 AB
WHEN
CHECKED
Vibration
151
frequency Hz
195
DURING
ADJUSTMENT
DURING
REPLACEMENT
163
213
185
Tension N
(lb)
294 490
(66 110)
Deflection
(Reference
value) mm
(in)
9.7 12.7
10.3 11.8
6.7 8.5
(0.38 0.50) (0.41 0.47) (0.26 0.34)
343 441
(77 99)
246
2 N m (16
588 784
(132 176)
2 ft-lb)
8 in-lb)
POWER STEERING
OIL PUMP PULLEY
TENSIONER
PULLEY
CRANKSHAFT
PULLEY
A/C
COMPRESSOR
PULLEY
AC100655 AB
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11A-10
WHEN
CHECKED
Vibration
115
frequency Hz
142
DURING
ADJUSTMENT
DURING
REPLACEMENT
123
147
135
441 539
(99 121)
169
Tension N
(lb)
392 588
(88 132)
637 833
(143 187)
Deflection
(Reference
value) mm
(in)
TENSIONER
PULLEY
B
AC100656 AB
CAUTION
Loosen the fixing nut A 1/8 - 1/2 of a revolution. If nut A is
loosened too much, the tension pulley will be more
inclined by the belt tension. Due to this, the belt deflection
may not be able to be adjusted.
1. Loosen the tension pulley fixing nut A behind the tension
pulley.
2. Adjust the belt deflection amount using the adjusting bolt B.
3. Tighten the fixing nut A.
Tightening torque: 26 4 N m (19 3 ft-lb)
CAUTION
Check after turning the crankshaft one or more rotations
clockwise.
4. Check the belt deflection amount and tension, and readjust
if necessary.
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11A-11
M1111001701008
16-PIN
MB991911
MB991824
MB991827
CAUTION
To prevent damage to scan tool MB991958, always turn the
ignition switch to the "LOCK" (OFF) position before connecting or disconnecting scan tool MB991958.
2. Connect scan tool MB991958 to the data link connector.
3. Set up a timing light.
4. Start the engine and run it at idle.
5. Check that the idle speed is approximately 700 r/min.
6. Select scan tool MB991958 MFI actuator test "item number
17."
7. Check that basic ignition timing is within the standard value.
Standard value: 5 BTDC 3
AK301038 AB
CAUTION
If the actuator test is not canceled, the forced drive will
continue for 27 minutes. Driving in this state could lead to
engine failure.
9. Press the clear key on scan tool MB991958 (select forceddrive stop mode), and cancel the actuator test.
10.Check that the actual ignition timing is at the standard value.
Standard value: Approximately 5 BTDC
NOTE: Ignition timing fluctuates about 7 Before Top Dead
Center, even under normal operating condition.
NOTE: It is automatically further advanced by about 5 to
10 Before Top Dead Center at higher altitudes.
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11A-12
M1111002100686
CAUTION
To prevent damage to scan tool MB991958, always turn the
ignition switch to the "LOCK" (OFF) position before connecting or disconnecting scan tool MB991958.
2. Connect scan tool MB991958 to the data link connector.
3. Confirm basic ignition timing is within the standard value.
(Refer to Ignition Timing Check P.11A-11.)
Standard value: 5 BTDC 3
16-PIN
MB991911
MB991824
MB991827
AK301038 AB
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11A-13
M1111003500933
CAUTION
To prevent damage to scan tool MB991958, always turn the
ignition switch to the "LOCK" (OFF) position before connecting or disconnecting scan tool MB991958.
2. Connect scan tool MB991958 to the data link connector.
3. Confirm basic ignition timing is within the standard value.
(Refer to Ignition Timing Check P.11A-11.)
Standard value: 5 BTDC 3
16-PIN
MB991911
MB991824
MB991827
AK301038 AB
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11A-14
M1111002601048
CRANKSHAFT POSITION
SENSOR CONNECTOR
WARNING
COMPRESSION GAUGE
AK100050AB
AK100050
5. Cover the spark plug holes with a shop towel etc. Crank the
engine for a few seconds to clear debris from a round the
spark plug holes. After the engine has been cranked, check
for foreign material adhering to the shop towel.
6. Install the compression gauge to one of the spark plug
holes.
7. Crank the engine with the throttle valve fully open and
measure the compression pressure.
Standard value (at engine speed of 200 r/min): 1,618
kPa (234 psi)
Minimum limit (at engine speed of 200 r/min): 1,176
kPa (170 psi)
8. Measure the compression pressure for all the cylinders, and
check that the pressure differences of the cylinders are
below the limit.
Limit: 98 kPa (14 psi)
9. If there is a cylinder with compression or a compression
difference that is outside the limit, pour a small amount of
engine oil through the spark plug hole, and repeat the
operations in steps 6 to 8.
(1) If the compression increases after oil is added, the cause
of the malfunction is a worn or damaged piston ring and/
or cylinder inner surface.
(2) If the compression does not rise after oil is added, the
cause is a burnt or defective valve seat, or pressure is
leaking from the gasket.
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11A-15
16-PIN
MB991911
MB991824
MB991827
AK301038 AB
VENTILATION
POSITIVE CRANKCASE HOSE
VENTILATION VALVE
PLUG
VACUUM
GAUGE
M1111002700547
AK301798 AB
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11A-16
M1111002800038
AK100052
CAUTION
As the purpose of this procedure is to apply the proper
amount of tension to the timing belt by means of the cam
drive torque, be sure not to rotate the crankshaft counterclockwise.
3. Remove the access cover.
4. Loosen the timing belt tensioner fixing bolt to apply tension
to the belt by means of the force of the tensioner spring.
CAUTION
Loosen the bolt 1/4 to 1/2 turn. If the belt is loosened more
than necessary, the bolt may fall inside the cover.
5. Tighten the timing belt tensioner fixing bolt.
6. Install the access cover.
7. Install the timing belt upper cover.
M1111002900574
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11A-17
3. With the engine idling, change the engine load (shift from N
to D range, for example) to make sure that there is no
change in the level of abnormal noise.
If there is a change in the level of abnormal noise, suspect a
tapping noise due to worn crankshaft bearing or connecting
rod bearing. (In this case, the lash adjuster is in good
condition.)
4. After completion of warm-up, run the engine at idle to check
for abnormal noise.
If the noise is reduced or disappears, clean the lash adjuster
(Refer to GROUP 11B Engine Overhaul <2.0L Engine>
Rocker Arms and Camshaft Inspection P.11B-21.) It is
suspected that the noise is due to collapse of the lash
adjuster. If there is no change in the level of the abnormal
noise, proceed to step 5.
5. Run the engine to bleed the lash adjuster system. (Refer
toP.11A-17.)
6. If the abnormal noise does not disappear after air bleeding
operation, clean the lash adjuster (Refer to GROUP 11B
Engine Overhaul <2.0L Engine> Rocker Arms and
Camshaft Inspection P.11B-21.)
.
GOOD
MAXIMUM
MINIMUM
AKX00328AB
HIGHPRESSURE
CHAMBER
AKX00329AB
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11A-18
2.
3.
APPROXIMATELY
3,000 r/min
IDLING
15 s
OPERATION
15 s
4.
ONE CYCLE
AKX00330 AD
5.
NOTE: If air mixed with oil enters the high pressure chamber
inside the lash adjuster from the above causes, air in the
high pressure chamber is compressed excessively while the
valve is being opened, resulting in an abnormal noise when
the valve closes.
This is the same phenomenon as that observed when the
valve clearance has become excessive. The lash adjuster
can resume normal function when air entered the lash
adjuster is removed.
Idle the engine for one to three minutes to warm it up.
Repeat the operation pattern, shown in left figure, at no load
to check for abnormal noise. (Usually the abnormal noise is
eliminated after repetition of the operation 10 to 30 times. If,
however, no change is observed in the level of abnormal
noise after repeating the operation more than 30 times,
suspect that the abnormal noise is due to some other
factors.)
After elimination of abnormal noise, repeat the operation
shown in left figure five more times.
Run the engine at idle for one to three minutes to make sure
that the abnormal noise has been eliminated.
ENGINE ASSEMBLY
REMOVAL AND INSTALLATION
M1112001001905
CAUTION
When the engine assembly replacement is performed, use scan tool MB991958 to initialize the
learning value (Refer to GROUP 00, Initialization Procedure for Learning Value in MFI Engine P.0023).
*: Indicates parts which should be temporarily tightened, and then fully tightened after installing
the engine into the vehicle.
Pre-removal Operation
Fuel Line Pressure Reduction [Refer to GROUP 13A, Onvehicle Service Fuel Pump Relay Disconnection (How
to Reduce Pressurized Fuel Lines) P.13A-961.]
Under Cover Removal
Engine Oil Draining [Refer to GROUP 00, Maintenance
Service Engine Oil (Change) P.00-51.]
Engine Coolant Draining (Refer to GROUP 14, On-vehicle
Service Engine Coolant Replacement P.14-27.)
Air Cleaner Removal (Refer to GROUP 15, Air Cleaner
P.15-4.)
Hood Removal (Refer to GROUP 42, Hood P.42-7.)
Radiator Removal (Refer to GROUP 14, Radiator P.1431.)
Front Exhaust Pipe Removal (Refer to GROUP 15,
Exhaust Pipe and Main Muffler P.15-14.)
Battery and Battery Tray Removal
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Post-installation Operation
Front Exhaust Pipe Installation (Refer to GROUP 15,
Exhaust Pipe and Main Muffler P.15-14.)
Radiator Installation (Refer to GROUP 14, Radiator P.1431.)
Air Cleaner Installation (Refer to GROUP 15, Air Cleaner
P.15-4.)
Drive Belt Tension Adjustment [Refer to GROUP 00,
Maintenance Service Drive Belts (Check Condition)
P.00-46.]
Engine Oil Refilling [Refer to GROUP 00, Maintenance
Service Engine Oil (Change) P.00-51.]
Engine Coolant Refilling (Refer to GROUP 14, On-vehicle
Service Engine Coolant Replacement P.14-27.)
Accelerator Cable Adjustment (Refer to GROUP 17, Onvehicle Service Accelerator Cable Check and Adjustment P.17-6.)
Hood Installation (Refer to GROUP42, Hood P.42-7.)
Battery and Battery Tray Installation
11A-19
17
5.0 1.0 Nm
44 9 in-lb
10
5
11
18
20
13
7
6
19
9
8
10 2 Nm
89 17 in-lb
12
14
15
16
4
21
3
2
AC100306AB
1.
2.
3.
4.
5.
6.
7.
8.
REMOVAL STEPS
ACCELERATOR CABLE
CONNECTION
A/C COMPRESSOR
CONNECTOR
POWER STEERING OIL
PRESSURE SWITCH
CONNECTOR
CRANKSHAFT POSITION
SENSOR CONNECTOR
MANIFOLD ABSOLUTE
PRESSURE SENSOR
CONNECTOR
EVAPORATIVE EMISSION
PURGE SOLENOID
CONNECTOR
EGR SOLENOID VALVE
CONNECTOR
IGNITION COIL CONNECTOR
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11A-20
27
5.0 1.0 Nm
44 9 in-lb
26
32
28
29 N
12 2 Nm
102 22 in-lb
67 7 Nm*
50 5 ft-lb*
44 10 Nm*
33 7 ft-lb*
24
30 N
25
22 4 Nm
16 3 ft-lb
31
12 2 Nm
102 22 in-lb
22 4 Nm
16 3 ft-lb
22
23
AC308426AB
<<A>>
<<B>>
<<C>>
>>D<<
<<C>>
>>D<<
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>>C<<
<<D>>
>>C<<
<<E>>
>>B<<
<<F>>
>>A<<
11A-21
CAUTION
Do not remove the flywheel mounting bolt shown by the
arrow. If this bolt is removed, the flywheel will become out
of balance and man be come damaged.
<M/T>: Refer to GROUP 22A P.22A-16.
<A/T>: Refer to GROUP 23A P.23A-343.
.
MB991895
MB991527
MB991454
AC306863 AB
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11A-22
MB991928
MB991527
MB991454
AC306865 AB
MB991527
MB991454
AC306753AB
.
MB991527
MB991454
AC306753AB
.
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11A-23
MB991895
MB991527
MB991454
AC306863 AB
MB991928
MB991527
MB991454
AC306865 AB
.
FUEL HIGHPRESSURE
HOSE
FUEL RAIL
CAUTION
Do not allow any engine oil to enter the fuel rail.
1. Apply a small amount of new engine oil to the O-ring.
2. While turning the fuel high-pressure hose to the right and
left, slide it into the fuel rail. Be careful not to damage the Oring. After installing, check that the hose turns smoothly.
3. If the hose does not turn smoothly, the O-ring is probably
binding. Disconnect the fuel high-pressure hose and check
the O-ring for damage. Replace if necessary.
4. Re-insert the fuel rail and confirm the hose turns smoothly.
O-RING
AC206397AB
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11A-24
CRANKSHAFT PULLEY
REMOVAL AND INSTALLATION
M1112001600506
182 4 Nm
134 3 ft-lb
(ENGINE OIL)
AC100305AB
1.
REMOVAL STEPS
POWER STEERING OIL PUMP
DRIVE BELT
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<<A>>
>>A<<
2.
3.
MD998719: Pin
11A-25
MD998719
MB990767
AC100791AC
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11A-26
M1112001900552
1
2
3.4 0.5 Nm
31 4 in-lb
10 2 Nm
89 17 in-lb
5
3 12
13
14 1 Nm
120 13 in-lb
31 3 Nm
23 2 ft-lb
10
22 4 Nm
16 3 ft-lb
11
14
15
6
8
7
9N
88 10 Nm
65 7 ft-lb
10 2 Nm
89 17 in-lb
1.
2.
3.
4.
5.
6.
7.
<<A>>
>>B<<
8.
AC202836 AC
REMOVAL STEPS
BREATHER HOSE
CONNECTION
PCV HOSE CONNECTION
ACCELERATOR CABLE CLAMP
ROCKER COVER
ROCKER COVER GASKET
SPARK PLUG GUIDE
TIMING BELT FRONT UPPER
COVER
CAMSHAFT SPROCKET
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<<B>>
<<B>>
>>A<<
11A-27
MD998719: Pin
CAUTION
Always turn the crankshaft in the forward direction (clockwise).
1. Turn the crankshaft in the forward direction (clockwise) to
align the timing mark so that No.1 cylinder is at TDC on the
compression stroke.
TIMING MARK
AC100792 AB
CAMSHAFT
SPROCKET
2. Secure the camshaft sprocket and the timing belt with tiewraps to prevent slippage between the camshaft sprocket
and the timing belt.
AC100799AB
CAUTION
Do not turn the crankshaft after the camshaft sprocket is
removed.
4. Remove the camshaft sprocket.
MD998719
AC100302 AB
CAUTION
Never disassemble the rocker arm and shaft assembly.
Loosen the rocker arm and shaft assembly mounting bolt, and
then remove the rocker arm and shaft assembly with the bolt
still attached.
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11A-28
MD998713
ACX00372 AC
MD998713
AC100788AB
MD998719
AC100302 AB
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11A-29
OIL PAN
REMOVAL AND INSTALLATION
M1112002801272
11 1 Nm
97 9 in-lb
5
24 3 Nm
18 2 ft-lb
9.0 3.0 Nm
79 26 in-lb
9.0 3.0 Nm
79 26 in-lb
49 6 Nm
37 4 ft-lb
9.0 3.0 Nm
79 26 in-lb
9.0 3.0 Nm
79 26 in-lb
4
39 5 Nm
29 3 ft-lb
7.0 1.0 Nm
62 9 in-lb
2
3
11 1 Nm
97 9 in-lb
AC100798 AB
<<A>>
>>C<<
>>B<<
1.
2.
3.
REMOVAL STEPS
DRAIN PLUG
DRAIN PLUG GASKET
LOWER OIL PAN
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<<B>>
>>A<<
>>A<<
4.
5.
6.
11A-30
CAUTION
Do not use oil pan FIPG cutter (MD998727) because the
upper oil pan is aluminum.
Use a wood block and hammer tapping against the lower oil
pan to loosen it.
CAUTION
Do not use oil pan FIPG cutter (MD998727) because the
upper oil pan is aluminum.
When individual mounting bolts are removed, insert a pry bar
into the gap (as shown in the figure) between upper oil pan and
cylinder block, and pry off upper oil pan.
AT THE BOLT
HOLE
AC100796 AB
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11A-31
E A
3. Using the letter symbols in the table below, install the upper
oil pan using the correct bolt. Refer to the table for proper
torque.
F
E
DESIGNATION
TIGHTENING
TORQUE
Flange Bolt
6 10
(0.2 0.4)
7.0
(62
1.0 N m
9 in-lb)
10
6 18
(0.2 0.7)
9.0
(79
3.0 N m
26 in-lb)
6 22
(0.2 0.9)
8 40
(0.3 1.6)
24 3 N m
(18 2 ft-lb)
10 40
(0.4 1.6)
49 6 N m
(37 4 ft-lb)
6 50
(0.2 2.0)
9.0
(79
6 127
(0.2 5.0)
Bolts with
Washers
AC100797 AB
3.0 N m
26 in-lb)
AT THE GROOVE
AA100011AB
3
2
6
10
11
9
8
5
1
AA100012AB
.
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11A-32
DRAIN PLUG
GASKET
ACX00364 AB
M1112003400489
N5
3
1
4
2
AC100955 AB
REMOVAL STEPS
TIMING BELT (REFER TO P.11A42.)
CRANKSHAFT POSITION
(REFER TO GROUP 16,
CRANKSHAFT POSITION
SENSOR P.16-49.)
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>>B<<
>>B<<
>>B<<
>>B<<
>>A<<
1.
2.
3.
4.
5.
11A-33
CRANKSHAFT
MD998717
MD998717
OIL SEAL
ACX00363AB
CRANKSHAFT
SENSING BLADE
CRANKSHAFT
SPROCKET
ENGINE
FRONT
CRANKSHAFT
SPACER
SPRING PIN
AA100007AB
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11A-34
M1112003700457
<M/T>
2
1
98 5 Nm
73 3 ft-lb
3
5
<A/T>
98 5 Nm
73 3 ft-lb
N8
6
7
AC100955 AB
REMOVAL STEPS
OIL PAN (REFER TO P.11A-29.)
TRANSAXLE ASSEMBLY (M/T:
REFER TO GROUP 22A,
TRANSAXLE ASSEMBLY P.22A16.)(A/T: REFER TO GROUP 23A,
TRANSAXLE ASSEMBLY P.23A343.)
CLUTCH COVER AND DISC <M/
T> (REFER TO GROUP 21B,
CLUTCH P.21B-2.)
<<A>>
>>B<<
<<A>>
>>B<<
>>A<<
1.
2.
3.
4.
5.
6.
7.
8.
MD998781
AA100001AB
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11A-35
ACX00356AB
MD998781
AA100001AB
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11A-36
M1112004001540
Pre-removal Operation
Fuel Line Pressure Releasing (Refer to GROUP 13A, Onvehicle Service P.13A-961.)
Engine Coolant Draining (Refer to GROUP 14, On-vehicle
Service Engine Coolant Replacement P.14-27.)
Under Cover Removal
Air Cleaner Removal (Refer to GROUP 15, Air Cleaner
P.15-4.)
Exhaust Manifold Removal (Refer to GROUP 15, Exhaust
Manifold P.15-11.)
Water Hose and Pipe Removal (Refer to GROUP 14,
Water Hose and Pipe P.14-41.)
Post-installation Operation
Water Hose and Pipe Installation (Refer to GROUP 14,
Water Hose and Pipe P.14-41.)
Exhaust Manifold Installation (Refer to GROUP 15,
Exhaust Manifold P.15-11.)
Air Cleaner Installation (Refer to GROUP 15, Air Cleaner
P.15-4.)
Engine Coolant Refilling (Refer to GROUP 14, On-vehicle
Service Engine Coolant Replacement P.14-27.)
Accelerator Cable Adjustment (Refer to GROUP 17, Onvehicle Service P.17-6.)
Under Cover Installation
5.0 1.0 Nm
44 9 in-lb
10
5
11
8
17
13
7
6
9
8
12
14
15
16
4
3
2
AC500237AB
1.
2.
3.
REMOVAL STEPS
ACCELERATOR CABLE
CONNECTION
A/C COMPRESSOR
CONNECTOR
POWER STEERING OIL
PRESSURE SWITCH
CONNECTOR
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4.
5.
6.
11A-37
7.
<COLD ENGINE>
74 4 Nm to 0 Nm to 20 2 Nm
to +90 to +90
55 3 ft-lb to 0 in-lb to 15 1 ft-lb
23
5.0 1.0 Nm
44 9 in-lb
18
19 N
20
(ENGINE OIL)
24
10 2 Nm
89 17 in-lb
25 N
22
21
31 3 Nm
23 2 ft-lb
88 10 Nm
65 7 ft-lb
AC308425 AC
>>D<<
>>D<<
REMOVAL STEPS
18. FUEL HIGH-PRESSURE HOSE
CONNECTION
19. O-RING
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<<A>>
>>C<<
11A-38
<<B>>
>>B<<
>>B<<
>>A<<
MD998719: Pin
CAUTION
Always turn the crankshaft in the forward direction (clockwise).
1. Turn the crankshaft in the forward direction (clockwise) to
align the timing mark so that number 1 cylinder is at TDC on
the compression stroke.
TIMING MARK
AC100792 AB
CAMSHAFT
SPROCKET
2. Secure the camshaft sprocket and the timing belt with tiewraps to prevent slippage between the camshaft sprocket
and the timing belt.
AC100799AB
CAUTION
Do not turn the crankshaft after the camshaft sprocket is
removed.
4. Remove the camshaft sprocket.
MD998719
AC100302 AB
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11A-39
CAUTION
Be careful not to damage or deform the plug guides when
removing the cylinder head bolts. Plug guides cannot be
replaced separately.
Using special tool MB991653, loosen the bolts in two or three
steps in the order of the numbers shown in the illustration, then
remove the bolts. Remove the cylinder head assembly.
MB991653
INTAKE SIDE
3
10
EXHAUST SIDE
AC100951 AB
(ENGINE OIL)
AC000143 AB
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11A-40
CAUTION
Always tighten cylinder head bolts at a 90 degree angle.
If it is less than 90 degree angle, the bolt will loosen.
If it is more than 90 degree angle, remove the head bolt
and repeat the procedure from step 1.
3. Using special tool MB991653, tighten the bolts by the
following procedure.
MB991653
STEP
OPERATION
(1)
(2)
Fully loosen.
(3)
(4)
Apply paint
tighten 90
(5)
Tighten 90
INTAKE SIDE
8
10
EXHAUST SIDE
AC100952 AB
STEP (4)
90
PAINTED MARKS
STEP (5)
90
REMARKS
PAINTED MARKS
AC000144 AB
MD998719
AC100302 AB
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11A-41
FUEL HIGHPRESSURE
HOSE
FUEL RAIL
CAUTION
Do not allow engine oil to enter the fuel rail.
1. Apply a small amount of new engine oil to the O-ring.
2. While turning the fuel high-pressure hose to the right and
left, slide it into the fuel rail. Be careful not to damage the Oring. After installing, check that the hose turns smoothly.
3. If the hose does not turn smoothly, the O-ring is probably
binding. Disconnect the fuel high-pressure hose and check
the O-ring for damage.
4. Re-insert the fuel rail and confirm the hose turns smoothly.
O-RING
AC206397AB
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11A-42
TIMING BELT
REMOVAL AND INSTALLATION
M1112004300991
12 2 Nm
102 22 in-lb
2
10 2 Nm
89 17 in-lb
12 2 Nm
102 22 in-lb
10 2 Nm
89 17 in-lb
23 2 Nm
17 1 ft-lb
5
12
49 5 Nm
36 4 ft-lb
9
7
49 9 Nm
37 7 ft-lb
23 3 Nm
17 2 ft-lb
10
11
10 2 Nm
89 17 in-lb
6
AC309191 AC
1.
2.
3.
4.
5.
6.
REMOVAL STEPS
CRANKSHAFT POSITION
SENSOR CONNECTION
TIMING BELT FRONT UPPER
COVER
PRESSURE HOSE CLAMP
POWER STEERING OIL LINE
BRACKET
GENERATOR ADJUSTING
BRACE
TIMING BELT LOWER COVER
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>>C<<
>>B<<
<<A>>
>>A<<
11A-43
TIMING MARK
CAMSHAFT
SPROCKE
TENSIONER
PULLEY
CAUTION
The crankshaft should always be turned only clockwise.
1. Turn the crankshaft clockwise (right turn) to align each
timing mark and to set the number 1 cylinder at compression
top dead center.
WATER PUMP
SPROCKET
TIMING MARK
CRANKSHAFT
SPROCKET
AA100002AB
TIMING BELT
TENSIONER
CAUTION
If the timing belt is to be re-used, use chalk to mark (on its
flat side) an arrow indicating the clockwise direction.
3. Place a screwdriver against the tensioner pulley and pry it
fully back in the direction of the arrow.
4. Temporarily tighten the tensioner pulley bolt.
5. Remove the timing belt.
BOLT
AA100003 AB
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11A-44
TIMING BELT
TENSIONER
BOLT
AA100004AB
CAUTION
After installing the timing belt, try to rotate the camshaft
sprocket in the reverse direction. Recheck to be sure that
the belt is fully tensioned and that each timing mark is in
the proper position.
1. With the timing belt tensioner pulley bolt loosened, use a
screwdriver to pry the tensioner pulley as close to the engine
mount as possible. Then temporarily tighten tensioner bolt.
2. Align each of the camshaft and crankshaft sprocket timing
marks.
3. Install the timing belt in the following order, while making
sure that the tension side of the belt is not loose.
(1) Crankshaft sprocket
(2) Water pump sprocket
(3) Camshaft sprocket
(4) Tensioner pulley
.
TIMING MARK
CAMSHAFT
SPROCKET
BELT
TENSION
SIDE
TENSIONER
PULLEY
TIMING
MARK
WATER PUMP
SPROCKET
CAUTION
As the purpose of this procedure is to apply the proper
amount of tension to the tension side of the timing belt by
using the cam driving torque, turn the crankshaft only by
the amount given below. Be sure not to turn the crankshaft
in the opposite direction (counter clockwise).
2. Turn the crankshaft in the proper rotation direction
(clockwise) for two rotations, and recheck to be sure that the
timing marks on each sprocket are aligned.
BELT
TENSION
SIDE
CRANKSHAFT
SPROCKET
AA100002 AC
CAMSHAFT
SPROCKET
AA100005AB
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FRONT ENGINE
CRANKSHAFT SPROCKET
FLANGE
CRANKSHAFT
AA100006AB
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11A-45
11A-46
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
M1112005800126
ITEM
SPECIFICATION
10
2 N m (89
5.0
1.0 N m (44
11
1 N m (97
9 in-lb)
22
4 N m (16
3 ft-lb)
14
1 N m (120
13 in-lb)
88
10 N m (65
7 ft-lb)
182
74 4 N m to 0 N m to 20 2 N m
to +90 to +90
(55 3 ft-lb to 0 in-lb to 15 1 ft-lb
to +90 to +90 )
98
5 N m (73
44
10 N m (33
67
7 N m (50
5 ft-lb)
49
5 N m (36
4 ft-lb)
5.0
1.0 N m (44
98
5 N m (73
3 ft-lb)
23
2 N m (17
1 ft-lb)
10
2 N m (89
17 in-lb)
31
3 N m (23
2 ft-lb)
11
1 N m (97
9 in-lb)
7.0
1.0 N m (62
39
5 N m (29
3 ft-lb)
22
4 N m (16
3 ft-lb)
49
9 N m (37
7 ft-lb)
12
2 N m (102
22 in-lb)
12
2 N m (102
22 in-lb)
12
2 N m (102
22 in-lb)
31
3 N m (23
3.4
0.5 N m (31
26
4 N m (19
3 ft-lb)
23
3 N m (17
2 ft-lb)
10
2 N m (89
17 in-lb)
10
2 N m (89
17 in-lb)
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17 in-lb)
4 N m (134
9 in-lb)
3 ft-lb)
3 ft-lb)
7 ft-lb)
9 in-lb)
9 in-lb)
2 ft-lb)
4 in-lb)
11A-47
ITEM
SPECIFICATION
M6
10
M6
18, M6
M8
40
M10
M6
22
40
50, M6
7.0
1.0 N m (62
9 in-lb)
9.0
3.0 N m (79
26 in-lb)
24
3 N m (18
2 ft-lb)
49
6 N m (37
4 ft-lb)
127 9.0
3.0 N m (79
26 in-lb)
SERVICE SPECIFICATIONS
M1111000300714
ITEM
STANDARD VALUE
115
142
392
588 (88
123
135
441
539 (99
147
169
637
833 (143
Approximately 5
BTDC
5 BTDC
CO content %
0.5 or less
1,618 (234)
132)
11.3 14.9
(0.44 0.59)
121)
12.0 13.9
(0.47 0.55)
187)
8.5 10.8
(0.33 0.43)
LIMIT
3
Minimum 1,176 (170)
98 (14)
700
100
99.4 (3.91)
HC contents ppm
100 or less
SEALANTS
Minimum 60 (18)
M1111000500387
ITEM
SPECIFIED SEALANT
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NOTES